Forthcoming and Online First Articles

International Journal of Materials Engineering Innovation

International Journal of Materials Engineering Innovation (IJMatEI)

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International Journal of Materials Engineering Innovation (11 papers in press)

Regular Issues

  • Experimental Analysis on Machinability Aspects of Sintered Aluminium Metal Matrix (Al+Si+Mg+Cu+SiC) Composite - A Novel Product Produced by Powder Metallurgy Method   Order a copy of this article
    by Rajesh Kumar Behera, Birajendu Prasad Samal, Sarat Chandra Panigrahi, Sudhansu Ranjan Das, Aezeden Mohamed, Kamalakanta Muduli, Ananya Samal, Pramod Kumar Parida, Ratnakar Das 
    Abstract: Due to the various superior and unique properties in aluminum metal matrix composites (Al+Si+Mg+Cu+SiC) on alloys; those are used in variety of industrial uses. Present paper studies the machinability aspects of turning and surface roughness in sintered aluminum metal matrix composites produced by powder metallurgy process and the various experiments were carried out by a CNC lathe with using tool inserts of titanium nitride coated tungsten carbide tool. This study attempts to measure and examine the influences of the depth of cut, feed-rate and cutting speed on surface roughness during machining of the composites. The cutting parameters and tool wear was influenced on the surface roughness. It was systematically analyzed and a predictive model was established with-respect-to turning variables using Taguchi and response-surface methodology. The results showed that feed and cutting speeds are important, controlled, and dominant factors in the AMMC turning operation, considering the minimization of machined surface roughness and the weight share of SiC reinforcement.
    Keywords: Aluminium Metal Matrix Composite; Turning; Response Surface Methodology (RSM); Taguchi method; Surface Roughness (SR).

  • Performance of SnO2/Al working electrode as an electrochemical biosensor for potassium(K+) ions   Order a copy of this article
    by Usharani Panda 
    Abstract: The erratic variation of potassium ion (K+) in the human body results in many life-threatening diseases relating to the kidney and heart. Hence, regular monitoring of the same is extremely essential for leading a healthy life. This encouraged us to fabricate an electrochemical biosensor using SnO2/Al as a working electrode to monitor K+ ions. The SnO2/Al working electrode was prepared from tin oxide (SnO2) coated on aluminum (Al) wire with the help of an indigenously designed chemically wet and dry (CWD) technique, followed by in-situ annealing at 400
    Keywords: Tin dioxide (SnO2); XRD; FESEM; I-V study; Real-time response; Sensitivity.

  • Effect of the Process Parameters on the Mechanical Properties of the Weld Joint in the Friction Stir Welding Process   Order a copy of this article
    by Sanjay Jha, Ravi Anand, PRASHANT PRAKASH 
    Abstract: This article predicts the effect of the input process parameters on the mechanical properties of the weld joint of the aluminum alloy in the friction stir welding process using statistical techniques that are ANOVA, regression and surface response methodology. In the statistical analysis, input factors are tool pin profile, welding speed and tool rotation speed and responses are mechanical properties such as tensile strength, percentage elongation and grain size. Experiments are carried out on the basis of taguchi method of design of experiments and the adequacy of the design of experiments is evaluated by ANOVA analysis. Responses surfaces of the mechanical properties with respect to the input parameters are developed using regression analysis. Statistical analysis shows that the quadratic model of regression analysis successfully represents the surface responses with all experiments conditions. Mechanical properties of the weld joint almost constant with welding speed at particular tool rotation speed and tool pin geometry. The effect of the tool rotation speed is nonlinear on the mechanical properties. At the moderate tool rotation speed (900 to 1120 rpm), tensile and percentage elongation are maximum, whereas grains size and hardness are minimum with all tool pin profiles and welding speed. The surface response curvatures are similar with all tool pin profiles. However, the numerical range of the surface response curvature depends on the tool pin profile. Steeped tool pin profile produces maximum tensile and percentage elongation whereas minimum hardness and grain size value among the all tool pin profile produced surface responses. Stepped tool pin profile produces superior mechanical properties of the weld joint with respect to other tool pin profiles.
    Keywords: Tool pin profile; Welding speed; Tool rotation speed; Response surface method; Mechanical Properties; Friction stir welding.

  • Analysis of high-speed CNC milling of Ti-6Al-4V by multi-objective crow optimization and multi-objective PSO   Order a copy of this article
    by Shubham Jain, Vishal Parashar 
    Abstract: Ti-6Al-4V is widely used as a functionally advanced material in different fields. Poor mechanization and absence of machining innovation are major issues in the application of Ti-6Al-4V. In this research, analysis of variance (ANOVA) and regression analysis have been used to make input-output relationships. The optimization method was applied to obtain the maximum Material Removal Rate (MRR) and minimum Surface Roughness (SR). These responses were optimized simultaneously and formulated as a multi-objective optimization problem. In multi-objective optimization, the weights of both responses were taken by the grey correlation analysis (GRA) method. This multi-objective optimization problem has been solved using two metaheuristic algorithms, namely, the Crow optimization algorithm, and the Particle swarm optimization (PSO). The optimization results show great concurrence with the response surface methodology results. Atomic force microscopy (AFM) was also used to visualize the effect of process parameters on the surface topography.
    Keywords: High-Speed CNC Milling; Ti-6Al-4V; Crow Optimization Algorithm; Particle Swarm Optimization; Atomic Force Microscopy.

  • Quantification of Surface Erosion in Polymeric Insulating Material under Electrical Stress using FTIR, SEM, and Edge Detection   Order a copy of this article
    by Chintan Patel, Ritesh Patel 
    Abstract: Silicon rubber (polymeric) insulators are extensively preferred in overhead power transmission networks due to their superior performance over the conventional insulators. The surface degradation is an important concern for the insulators as it is organic in nature. The degradation may be caused by variety of factors like electrical and environmental stresses which will result in failure of the insulator. This paper discusses the surface erosion study of silicon rubber by applying 3.5 kV voltages (AC and DC with both the polarities) as per IEC 60587. To quantify the surface erosion, Fourier transform infrared (FTIR) and scanning electron microscopy (SEM) have been used. Further, the results are verified by edge detection techniques using Sobel and Prewitt edge detection algorithm. The study revealed that the surface erosion is more with positive DC voltage than AC and negative DC which demands the introduction of appropriate filler materials to enhance the surface properties of the silicon rubber.
    Keywords: silicon rubber insulator; surface degradation; erosion; IP test; Fourier transform infrared; FTIR; scanning electron microscopy; SEM; edge detection.
    DOI: 10.1504/IJMATEI.2022.10042421
    by Aezeden Mohamed, Willie Doaemo, Kamalakanta Muduli 
    Abstract: Fly ash is a fine powder produced by coal combustion in thermal energy plants before the release of gas into the atmosphere. This industrial by-product may be below the standard building materials, but it is advantageous to good performance because of its low cost. This study reviews the literature to investigate the properties and improvement of fly ash/fibre as a concrete substitute compared to fibre, silica fumes, cocoon fibres and other agents. Furthermore, because fly ash is widely considered a concrete pozzolan, it will open the way for more sustainable solid waste management through industrial waste and sustainable materials combined with organically available plant materials such as cocoa and rice husk.
    Keywords: concrete; coconut fibre; fly ash; moisture content; sustainable concrete.
    DOI: 10.1504/IJMATEI.2022.10042422
  • Composite Tiles from Waste Plastics and Fly-ash: Modelling the influence of composition on mechanical and physical properties   Order a copy of this article
    by Sampa Chakrabarti, Abhijit Bandyopadhyay, Sayantan Adak 
    Abstract: Fly-ash is a waste from coal-based thermal power plant. Grocery bags commonly made from polyethylene and packaging foam which is expanded polystyrene are also two types of waste plastics. All these solid wastes pose an environmental threat. In this article, development of composite tiles from these solid wastes and their physico-mechanical characterisation has been described. Mass ratios of polyethylene to fly-ash (A) and polystyrene to fly-ash (B) were correlated with the respective solvent resistances, tensile and flexural strengths of the tiles through simple equations. The agreement of the proposed models and the experimental data was found to be excellent. Indian Standard for the common ceramic tiles is compared with the developed ones. The product is found suitable as a wall tile. This may help in sustainable disposal of these bulk solid wastes whose safe disposal is still a huge problem.
    Keywords: waste thermocol; polyethylene bag; fly-ash; composite tiles; mechanical strength; solvent absorption; model.
    DOI: 10.1504/IJMATEI.2022.10042423
  • Wear Resistance Performance of Sheet Metal Die Materials: A Review   Order a copy of this article
    by Sachin Salunkhe, Jayavelu Sundaram, Pavan Chandankar, C. Rajkumar 
    Abstract: The high and ultra-high strength steel materials are widely used in sheet metal forming processes such as stamping, bending, piercing, etc. in the automotive industry. Because of a strong adhesive propensity between the tool and the surface, the wear of the tool is created. The wear of the tool affects the dimensional property of the products, problems of surface quality and consequently interruptions of production. The wear behaviour and wear mechanisms of sheet metal dies were studied in this paper. This paper focuses on recent developments in tribological tool wear and provides adequate data on tool wear features.
    Keywords: wear; sheet metal dies; wear mechanism; tribological.
    DOI: 10.1504/IJMATEI.2022.10042828
  • Influence of high temperature sodium exposure on microstructure and material properties of AISI 440C Stainless Steel   Order a copy of this article
    by S. C. S. P. Kumar Krovvidi, Chitta Ranjan Das, Punnia Moorthy R, Chandramouli S, Mariappan K, Sreedhar B. K, Jose Varghese, Nashine B.K., Shaju K. Albert, Raghupathy S 
    Abstract: AISI 440C SS is one of the candidate materials for bearings in sodium-cooled fast reactor systems due to its good mechanical strength and chemical inertness compared to other bearing steels such as 100Cr6. To understand the influence of sodium exposure at the operating temperature on the properties of the steel, a systematic study of exposing this material in static sodium for 1 month and 8 months was carried out at 550
    Keywords: AISI 440C SS; bearings for SFR systems; sodium exposure; tempered martensite; leaching of carbon.
    DOI: 10.1504/IJMATEI.2022.10044092
  • Optimization of Wire EDM process parameters using Taguchi Technique for machining of Hybrid Composites   Order a copy of this article
    by S. Jebarose Juliyana, Uday Praksh, Sachin Salunkhe 
    Abstract: In the mechanical industry, properties of high toughness, rigidity, and impact resistance are in high demand. Over the last two decades, machine tools have grown rapidly, but they are still not widely employed to their full potential. The difficulty of achieving effective parameters has attracted the interest of investigators and engineers. In this investigation, stir cast aluminium matrix composites (AMC-LM5/6%ZrO2/2,3,4%Graphite) were utilised to find the optimal process parameters in WEDM. The importance of improving MRR in WEDM machining cannot be under estimated. To get the intended effects, the trials were conducted by means of the Taguchi approach L27 orthogonal array. ANOVA determines the outcome of machining parameters that influence the normal characteristics as well as the relative contribution of machining parameters. The S/N ratio analysis identifies the parameter that has the greatest influence. The experimental MRR is 9.30 mm3/min, while predicted MRR is 9.46 mm3/min.
    Keywords: AMCs; Taguchi technique; WEDM; ANOVA; S/N ratio.
    DOI: 10.1504/IJMATEI.2022.10044095
  • Effect of HVOF Coatings on Abrasive Wear Behavior of Martensitic Stainless Steel   Order a copy of this article
    by Sachin Tejyan, Sumit Rana, Amar Patnaik 
    Abstract: The purpose of this work is to study the effect of HVOF coatings on the hardness and abrasive wear behaviour of martensitic stainless steel. Three types of powders, i.e., WTiC-Ni, WC-Co-Cr, and Cr3C2Ni-Cr are used for thermal sprayed HVOF coatings. The abrasive wear behaviour of coated martensitic stainless steel is characterised by varying wheel speed (100, 150, 200, and 250 rpm), abrading distance (1,000, 2,000, 3,000 and 4,000 m), and load (10, 20, 30, and 40 N). Taguchi designs have also been implemented to examine the effect of control factors, i.e., type of coating, speed, and load. Experimental results reveal that the wear resistance of coated martensitic stainless steel improves with each type of coating. Experimental results also show that the abrasive wear resistance of the WC-Co-Cr powder-coated martensitic stainless steel surface is highest as compared to other coatings, i.e., Cr3C2Ni-Cr and WTiC-Ni.
    Keywords: martensitic stainless steel; HVOF coatings; abrasive wear; microstructure.
    DOI: 10.1504/IJMATEI.2022.10044097